Mercedes-Benz ML320. Manual - part 643

SM63.20-P-0003GI

Reinforce right front engine hood hinge support

16.1.02

MODELS  163.136 /154 /172 #A as of 145273, 
163.136 /154 /172 #X as of 708319, 
163.113 /128 /174 /175

P63.20-3439-12

The template shown is for the left side
(turn over for the right side)

6

Template

7

Hole, hinge assembly bolt, rear

8

Hole, hinge assembly bolt, front

9

Center punch position

10

Center punch position

11

Center punch position

a

80 mm

b

100 mm

P63.20-3435-06

1

Hinge assembly bolt, front

2

Hinge assembly bolt, rear

3

Center punch mark

4

Center punch mark

5

Center punch mark

Operation no. of operation texts or standard texts and flat rates

Range

Op. no.

Operation text

Time

Acc. no.

Code

P

023540

REINFORCE LEFT ENGINE HOOD HINGE SUPPORT

037 WU/3.1 hrs.

88 237 36

---

P

023541

REINFORCE RIGHT ENGINE HOOD HINGE SUPPORT

040 WU/3.3 hrs.

88 237 36

---

P

023542

REINFORCE (BOTH) ENGINE HOOD HINGE SUPPORTS

053 WU/4.4 hrs.

88 237 36

---

  

Remove/install

1

Ensure that the recirculated air function is 
deactivated

2

Remove engine hood

AR88.40-P-3000GH

Copyright DaimlerChrysler AG  09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

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3

Remove engine hood hinge on the front 
passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A

 

Danger!

Risk of explosion from explosive gas. Risk 
of poisoning and caustic burns from 
swallowing battery electrolyte. Risk of injury 
through burns to skin and eyes from battery 
acid or when handling damaged lead-acid 
batteries

No fire, sparks, naked flames or smoking. 
Wear protective gloves, acid-resistant 
clothing and safety glasses. Pour battery 
electrolyte only into suitable and appropriately 
marked containers.

AS54.10-Z-0001-01A

4

Remove battery

AR54.10-P-0005GH

5

Remove air conditioning blower motor

AR83.30-P-5560GH

6

Print out template (6) and adapt the size to 
the correct dimensions (a, b)

Determine ACTUAL dimension (a) from the 
drawing.

Divide the SPECIFIED dimension (a) by the 
determined ACTUAL dimension (a) and copy 
the template to the original size with the 
corresponding factor.

 Check dimensions for both axles.

7

Cut out template

8

Cut out holes (7, 8) for engine hood hinge 
studs

9

Position template in the engine hood hinge 
support using the stud holes

 The template is drawn for the left side. 

Turn over to obtain the right side.

10

Center the engine hood hinge support on the 
template using the markings (9, 10, 11)

11

Remove template

12

Drill a hole at each center punch mark (3, 4, 5)

 Only drill through the 2 upper panels. Do 

not drill through the reinforcement panel (3rd 
panel).

 

*201589005100

13

Cover windshield, paint surface and adjacent 
components adequately in order to avoid 
damage due to welding work

 Cover apertures in the body in order to 

prevent flying sparks: the foam in the 
instrument panel burns easily.

c

 

General information on repairs to body

AH60.00-N-0001-01A

 

Danger!

The high voltage used for arc welding 
presents a lethal hazard. Explosion hazard 
when welding in area of materials easily 
inflammable. Injury hazard  from welding 
spatter and UV-light while welding. Risk of 
poisoning when inhaling welding vapors.

Use insulating mats. Wear protective clothing, 
safety glasses, and protective mask. Remove 
highly inflammable materials from the danger 
zone. Use air extractor.

AS00.00-Z-0007-01A

14

Plug weld each hole

*WE58.40-Z-1005-02A

15

Plug welds should be flat and ground smooth

16

Remove covers and clean the repair area

17

Prime untreated points in the area of the 
engine hood hinge support

18

Prime the underside of the reinforcement 
panel of the engine hood hinge

 Access to underside of engine hood hinge 

support through the recess for the wiper motor.

19

Spray the underside of the reinforcement 
panel of the engine hood hinge support with 
wax preservative

 Access to underside of engine hood hinge 

support through the recess for the wiper motor.

20

Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers (see Workshop Equipment Manual)

WE58.40-Z-1005-02A

MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

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Number

Designation

Order number

BR00.45-Z-1004-01A

MB body sealant for sealing seams (suitable for painting)

001 989 63 20

Parts ordering notes

Part no.

Designation

Quantity

000 986 06 50

Priming stick

1

000 986 33 70 10

Wax preservative

1

Copyright DaimlerChrysler AG  09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

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AR88.40-P-3200GI

Remove/install engine hood lock

9.4.99

MODEL 

163.136 /154 /172 #A as of 145273, 

163.136 /154 /172 #X as of 708319, 
163.113 /128 /157 /174 /175

P88.40-2058-06

1

Screws

2

Engine hood lock bottom section

3

Engine hood control cable

4

Electrical connector

5

Screws

6

Engine hood lock top section

 

 

Removing and installing

1

Open engine hood and raise to vertical position

AR88.40-P-1000GI

2

Unscrew screws (1) and remove engine hood 
lock bottom section (2) upward

 

*BA88.40-P-1003-01C

3.1

Disconnect electrical connector (4) from 
engine hood lock bottom section (2)

 Only when equipped with ATA.

4

Unhook engine hood control cable (3) from 
engine hood lock bottom section (2)

 Pull out engine hood control cable slightly.

5

Remove engine hood lock bottom 
section (2) 

 

Installation: Ensure that engine hood 

control cable is routed carefully.

6

Unscrew screws (5) and remove engine hood 
lock top section (6) 

 Mark installation position for engine hood 

lock top section on engine hood.

 

*BA88.40-P-1004-01C

7

Install in the reverse order

8

Check alignment of engine hood

 If necessary:

#

Adjust engine hood

AR88.40-P-3020GH

9

Lubricate engine hood lock

e

 

Lubricate hood lock, safety hook and hinges

AP88.40-P-8821GH

10

Perform function check

11

Check function of safety hook

 For this purpose, close engine hood, 

unlock and check arrest on radiator cross 
member.

 

Engine hood

Number

Designation

Model 163

BA88.40-P-1003-01C

Screw for engine hood lock on radiator cross 
member

Nm

12

BA88.40-P-1004-01C

Screw for engine hood lock top section on engine 
hood

Nm

12

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